Protective headgear

ABSTRACT

A boltless retention system for a protective headgear includes a pad boltlessly secured within a cavity of the protective headgear. A strap is boltlessly secured within the cavity and between the pad and an inner surface of the headgear. The strap withstands a static pull strength between about 150 pounds and 300 pounds.

This application claims the benefit of U.S. Provisional Application No.61/332,686, filed May 7, 2010, which is hereby incorporated byreference.

BACKGROUND

The present invention relates to a retention system. It finds particularapplication in conjunction with a protective headgear retention systemand will be described with particular reference thereto. It will beappreciated, however, that the invention is also amenable to otherapplications.

Current protective headgear retention systems typically use standardmetallic fasteners (e.g., bolts) to secure a retention system to aprotective headgear (e.g., helmet). To use such standard fasteners,manufacturers create holes through the protective headgear by, forexample, drilling. The fasteners are then secured in the respectiveholes. Respective straps are then secured to the fasteners. The strapsare releasably secured together under a user's chin by, for example, abuckle.

Ballistic resistant protective headgear, such as ballistic helmets forlaw enforcement an military applications, are primarily comprised ofhigh-performance fiber reinforced composite materials that are notamenable to fabrication processes that could provide an attachment pointfor the retention system. In addition, creating the holes in theprotective helmet requires additional steps during the manufacturingprocess. Another consideration is the weight added to the protectivehelmet by the metallic fasteners.

The present invention provides a new and improved apparatus forboltlessly securing a retention system to a protective headgear.

SUMMARY

In one embodiment, a boltless retention system for a protective headgearincludes a pad boltlessly secured within a cavity of the protectiveheadgear. A strap is boltlessly secured within the cavity and betweenthe pad and an inner surface of the headgear. The strap withstands astatic pull strength between about 150 pounds and 300 pounds.

BRIEF DESCRIPTION OF THE DRAWINGS

In the accompanying drawings which are incorporated in and constitute apart of the specification, embodiments of the invention are illustrated,which, together with a general description of the invention given above,and the detailed description given below, serve to exemplify theembodiments of this invention.

FIG. 1 illustrates a perspective view of a protective headgear inaccordance with one embodiment of an apparatus illustrating principlesof the present invention;

FIG. 2 illustrates an inside view of the protective headgear helmet ofFIG. 1 showing a schematic representation of a boltless retention systemin accordance with one embodiment of an apparatus illustratingprinciples of the present invention;

FIG. 3 illustrates a schematic representation of a the boltlessretention component of FIG. 2;

FIG. 4 illustrates a protective headgear helmet showing a schematicrepresentation of a boltless retention system in accordance with asecond embodiment of an apparatus illustrating principles of the presentinvention;

FIG. 5 illustrates a cross-sectional view of the protective headgearhelmet and boltless retention system of FIG. 4;

FIG. 6 illustrates various schematic representations of differentboltless retention component designs;

FIG. 7 illustrates a graph of load vs. extension from preload for three(3) of the designs of FIG. 6;

FIG. 8 illustrates a perspective view of a protective headgear helmetshowing a schematic representation of a boltless retention system inaccordance with a third embodiment of an apparatus illustratingprinciples of the present invention; and

FIG. 9 illustrates a top view of a pad of FIG. 8, which has beensubstantially flattened.

DETAILED DESCRIPTION OF ILLUSTRATED EMBODIMENT

With reference to FIG. 1, a perspective view of a helmet portion 8 of aprotective headgear 12 including an exemplary boltless retention system10 is illustrated in accordance with a first embodiment of the presentinvention. With reference to FIG. 2, a view inside a cavity 11 of thehelmet portion 8 is illustrated in accordance with the first embodimentof the present invention. In the illustrated first embodiment, theboltless retention system 10 includes the protective headgear 12, thehelmet portion 8, and a retention component 14. The protective headgear12 is of a known material (e.g., phenolic-polyvinyl butryl (PVB) coatedwoven aramid fabric), which provides ballistic and impact protection toa user wearing the headgear 12.

With reference to FIGS. 1-3, the retention component 14 includes asubstrate (e.g., a platform) 16, a strap 20, and a buckle 22. In oneembodiment, the substrate 16 is a piece of material including a firstsecuring means 24 on a first face 26 (e.g., the back face) (see FIG. 3).The first securing means 24 in this embodiment is contemplated to be anadhesive such as polyurethane, epoxy, polyacrylate,styrene-butadiene-styrene, cyanoacrylate, glue, thermally activatedglue, or other suitable adhesive. The substrate 16 also includes asecond securing means 30 on a second face 32 (e.g., the front face) (seeFIGS. 1-3). The second securing means 30 in this embodiment iscontemplated to be one portion of a hook-and-loop fastener (e.g., eithera hook portion or a loop portion of a hook-and-loop fastener such as aVELCRO® hook-and-loop fastener).

The strap 20 is secured to the substrate 16. In the illustratedembodiment, the strap 20 is secured to the second (front) face 32 of thesubstrate 16. A third securing means 34 secures the strap 20 to thesubstrate 16. The third securing means 34 includes a stitching (e.g., abox stitching) that passes through the strap 20 and the substrate 16. Inone embodiment, the stitching includes 8-10 stitchings per inch using aT-45 bonded Anefil Nylon® twisted filament thread, or some otherrelatively strong thread that resists deterioration. Including less than8-10 stitchings per inch may cause the strap 20 to “pucker” and may (ormay not) reduce the strength of the connection of the strap 20 to thesubstrate 16 (depending on how many fewer stitchings than 8-10stitchings per inch are used). On the other hand, including more than8-10 stitchings per inch may cause the connection between the strap 20and the substrate 16 to weaken by, for example, weakening the substrate16 and/or the strap 20.

In order to provide adequate strength, the substrate 16 is greater thanor equal to about 2 inches². In one embodiment, the substrate 16 is atleast 3″×3″. The strap 20 is contemplated to be about ¾″ wide and 5 ¼″long. As illustrated, the strap 20 is positioned across the substrate 16with one of the shorter edges 36 of the strap 20 proximate to an edge 40of the substrate 16. The strap 20 is also substantially centered on thesubstrate 16 so that approximately equal portions of the substrate 16are on either side along the length of the strap 20.

In the illustrated embodiment, the stitching 34 is about 1 ¾″ long andabout ⅝″ wide. One edge 42 of the stitching 34 is between about ⅞″ andabout 1″ from an edge 44 of the substrate 16 beyond which the strap 20extends (i.e., an edge of the substrate 16 that is proximate to the edgeof the strap 20). The about ⅞″ or about 1″ between the edge 44 of thesubstrate 16 and the edge 42 of the stitching 34 provides flexibility tothe strap (for added comfort to the user) while maintaining a secureconnection between the strap 20 and the substrate 16.

Although the strap 20 is illustrated as secured to the second (front)face 32 of the substrate 16, it is also contemplated that the strap 20may be secured to the first (back) face 26 of the substrate 16.

The substrate 16 and the strap 20 are of a fabric material. In oneembodiment, the strap 20 is a “webbing” material.

The buckle 22 is illustrated as a locking bar (e.g., a ladder lock)securing mechanism to secure the straps 20 beneath a user's chin (e.g.,at least one of the straps runs under the user's chin). However, othertypes of buckles are contemplated.

As discussed above, the second securing means 30 on the front face 32 ofthe substrate 16 is contemplated to be one portion of a hook-and-loopfastener (e.g., either a hook portion or a loop portion of ahook-and-loop fastener such as a VELCRO® hook-and-loop fastener). Theportion of a hook-and-loop fastener on the front face 32 of thesubstrate 16 provides a means for securing optional one or more pads 46,which are used for providing comfort and achieving a better fit. Thepad(s) 46 may be removably secured at various locations on the substrate16.

One example of the substrate 16 is a VELCRO® Part #151931, whichprovides a static pull strength of between about 200 pounds and 300pounds.

FIG. 4 illustrates a simplified component diagram of a second embodimentof an exemplary boltless retention system 10′. In the second illustratedembodiment, the boltless retention system 10′ includes pass-throughopenings 60 in the protective headgear 12′. FIG. 5 illustrates across-sectional view of the protective headgear 12′ with the straps 20′passing through the opening 60.

With reference to FIG. 6, various schematic representations of differentboltless retention component designs are illustrated. A first design 70includes a small Kevlar fabric backing, a 3″×3″ hook tape, and a 1″overlap of lanyard onto substrate. A second design 72 includes no Kevlarfabric backing, a 3″×3″ hook tape, a 2.75″ overlap of lanyard ontosubstrate, and an X-stitch. A third design 74 includes no Kevlar fabricbacking, a 3″×3″ hook tape, a 2.75″ overlap of lanyard onto substrate,and three (3) parallel stitches. A fourth design 76 includes no Kevlarfabric backing, a 3″×3″ hook tape, a 2.75″ overlap of lanyard ontosubstrate, and a large rectangular stitch to edge of substrate. A fifthdesign 80 includes no Kevlar fabric backing, a 3″×3″ hook tape, a 2.75″overlap of lanyard onto substrate, and a stitch ⅞″ to 1″ from the edgeof the substrate (see FIG. 3).

FIG. 7 illustrates a graph of load (pounds) vs. extension from preload(millimeters) for three (3) of the designs (i.e., the second, third, andfifth designs 72, 74, 80, respectively) of FIG. 6. In the illustratedgraph, each of the second, third, and fifth designs 72, 74, 80,respectively, failed between 150 lbs. and 300 lbs. The extension frompreload axis represents how far the retention component stretched beforefailing.

It is typically desirable for the chinstrap assembly to fail at a loadgreater than the requirement, but below 300 lbs of force (e.g., towithstand a static pull strength of less than 300 lbs.) to ensure thehelmet portion 8 can release under extreme duress to reduce/minimizeneck and head trauma. From FIGS. 6 and 7, it can be seen that all threeof the second, third, and fifth designs 72, 74, 80, respectively, meetthe performance requirement of >150 lbs. of force at failure. The secondand third designs 72, 74, respectively, (Graphs 82, 84, respectively)meet the minimum load requirement (static pull strength) of >150 lbs,and approach the upper desired (static pull strength) limit of 300 lbs.,with failure loads (static pull strengths) of about 245 lbs. and about265 lbs, respectively. In addition, the fifth design 80 (Graph 86) isrelatively easier to manufacture, has relatively improved materialinteraction (e.g., the), and is relatively more readily removable(because, for example, the X-Stitch assembly in second design 72 and theparallel stitch assembly in third design 74 includes stitching closer toall of the edges relative to the fifth design 80) in the case that thehelmet portion's chinstrap assembly requires replacement. The thirddesign 74 typically requires a lifting of the stitch during processingwhich adds time to the process.

FIG. 8 illustrates a simplified component diagram of a third embodimentof an exemplary boltless retention system 10″. In the third illustratedembodiment, the boltless retention system 10″ includes a pad 100 (e.g.,a unitary pad) secured within the cavity 11″ of the protective headgear12″. The pad 100 is boltlessly secured within the cavity 11″. Forexample, the pad 100 is sized to frictionally fit within the cavity 11″.Alternatively, it is also contemplated that the pad 100 is secured to aninner surface of the helmet portion 8″ via, for example, a hook-and-loopfastener.

It is contemplated that the straps 20″ are secured between the pad 100and the inner surface of the helmet portion 8″. Two embodiments forsecuring the straps are illustrated in FIG. 8. In one embodiment, thestrap 20 a″ is secured directly to the pad 100 (and, also, possibly tothe inner surface of the helmet portion 8″) via, for example, ahook-and-loop fastener. It is also contemplated that the strap 20 a″ issecured directly to the inner surface of the helmet portion 8″ via, forexample, a hook-and-loop fastener or an adhesive. In another embodiment,the strap 20 b″ is boltlessly secured to the pad 100 via, for example, asubstrate 16″ and a hook-and-loop fastener (as discussed above).Alternatively, the substrate 16″ may be secured to the inner surface ofthe helmet portion 8″ using an adhesive. Although both embodiments forsecuring the strap between the pad 100 and the inner surface of thehelmet portion 8″ are illustrated in FIG. 8, typically only one or theother embodiment would be used with a particular headgear 12″.

FIG. 9 illustrates one embodiment of a design for the unitary pad 100.In the illustrated embodiment, the pad 100 is flattened and includesvarious “cut-outs.” When the flattened pad 100 is fit into the cavity11, various edges of the cut-outs come into contact with one another toform a single, continuous pad covering most of the inner surface of thehelmet portion 8″. FIG. 9 illustrates an embodiment in which the straps20 a″ are secured to a surface of the pad 100 contacting the innersurface of the helmet portion 8″. As discussed above, in thisembodiment, the straps are secured to the pad 100 via a hook-and-loopfastener. A similar pad may be used if the straps and/or substrates aresecured to the inner surface of the helmet portion 8″ instead.

It is to be understood that the various sizes, lengths, and designs ofthe straps 20″ and/or substrates 16″ in FIGS. 8 and 9 are discussedabove with reference to the other embodiments. For example, if asubstrate is used, a strap may be boltlessly secured to the substrateusing a stitching pattern as discussed above.

While the present invention has been illustrated by the description ofembodiments thereof, and while the embodiments have been described inconsiderable detail, it is not the intention of the applicants torestrict or in any way limit the scope of the appended claims to suchdetail. Additional advantages and modifications will readily appear tothose skilled in the art. Therefore, the invention, in its broaderaspects, is not limited to the specific details, the representativeapparatus, and illustrative examples shown and described. Accordingly,departures may be made from such details without departing from thespirit or scope of the applicant's general inventive concept.

1. A protective headgear, comprising: a helmet portion; a substratesecured to the helmet portion; an adhesive on a first face of thesubstrate for adhering the substrate to the helmet portion; and a strapsecured to the substrate, the strap remaining secured to the substrateand the substrate remaining secured to the helmet portion to a staticpull strength between about 150 pounds and 300 pounds.
 2. The protectiveheadgear as set forth in claim 1, wherein: the strap is secured to asecond face of the substrate.
 3. The protective headgear as set forth inclaim 1, wherein: the adhesive is an epoxy.
 4. The protective headgearas set forth in claim 2, further including: a stitching through thestrap and the substrate to secure the strap to the substrate.
 5. Theprotective headgear as set forth in claim 4, wherein: the stitchingincludes about 8 stitches to about 10 stitches per inch.
 6. Theprotective headgear as set forth in claim 5, wherein: the substrate isat least 2″ by 2″; and the strap is about 5 ¼″ long by about ¾″ wide. 7.The protective headgear as set forth in claim 6, wherein: the strap issubstantially centered on the substrate and positioned across thesubstrate with one of the about ¾″ wide edges of the strap proximate toone of the edges of the substrate.
 8. The protective headgear as setforth in claim 7, wherein: the stitching is about 1 ¾″ long and about ⅝″wide; one of the about ⅝″ wide edges of the stitching is proximate theedge of the substrate that is proximate to one of the about ¾″ edges ofthe strap; and the other of the about ⅝″ wide edges of the stitching isbetween about ⅞″ and about 1″ from an opposite edge of the substratethat is proximate to one of the about ¾″ edges of the strap.
 9. Theprotective headgear as set forth in claim 1, wherein: the strap extendsaround a user's chin to secure the user's head in the helmet portion.10. A boltless retention system for a protective headgear, the boltlessretention system comprising: a pad boltlessly secured within a cavity ofthe protective headgear; and a strap boltlessly secured within thecavity, and between the pad and an inner surface of the headgear, thestrap withstanding a static pull strength between about 150 pounds and300 pounds.
 11. The boltless retention system for a protective headgearas set forth in claim 10, wherein: the pad is sized to frictionally fitwithin the cavity of the protective headgear; and the strap is securedto the pad with a hook-and-loop fastener.
 12. The boltless retentionsystem for a protective headgear as set forth in claim 10, wherein: thepad is secured to the inner surface of the headgear with a hook-and-loopfastener; the strap is secured to the pad with a hook-and-loop fastener;and the strap is secured to the inner surface of the headgear with ahook-and-loop fastener.
 13. The boltless retention system for aprotective headgear as set forth in claim 10, further including: asubstrate; wherein the strap is boltlessly secured to the substrate; andwherein the substrate is boltlessly secured to the inner surface of theheadgear.
 14. The boltless retention system for a protective headgear asset forth in claim 13, wherein: the strap is stitched to the substrate.15. The boltless retention system for a protective headgear as set forthin claim 14, wherein: the substrate is secured to the inner surface ofthe headgear with a hook-and-loop fastener.
 16. The boltless retentionsystem for a protective headgear as set forth in claim 14, wherein: thesubstrate is secured to the inner surface of the headgear with anadhesive.
 17. The boltless retention system for a protective headgear asset forth in claim 16, wherein: a first face of the substrate is securedto the inner surface of the protective headgear with the adhesive; andthe strap is stitched to a second face of the substrate.
 18. Theboltless retention system for a protective headgear as set forth inclaim 14, wherein: the substrate is at least about 2 inches²; and thestrap is about 5 ¼″ long and about ¾″ wide.
 19. The boltless retentionsystem for a protective headgear as set forth in claim 18, wherein: thestrap is stitched to the substrate using a box-stitching design andincludes about 8 to about 10 stitchings per inch.
 20. The boltlessretention system for a protective headgear as set forth in claim 19,wherein: the box-stitching is about 1 ¾″ long and about ⅝″ wide.
 21. Theboltless retention system for a protective headgear as set forth inclaim 10, further including: a substrate; wherein the strap isboltlessly secured to the substrate via a stitching; and wherein thesubstrate is secured to the pad with a hook-and-loop fastener.
 22. Aprotective headgear, comprising: a helmet portion; a pad sized tofrictionally fit within a cavity of the helmet portion; a first strapboltlessly secured to the pad, the first strap being positioned betweenthe pad and an inner surface of the headgear, and the first strapwithstanding a static pull strength between about 150 pounds and 300pounds; and a second strap boltlessly secured to the pad, the secondstrap being positioned between the pad and an inner surface of theheadgear, and the second strap withstanding a static pull strengthbetween about 150 pounds and 300 pounds, the first and second strapscapable of being secured together so that at least one of the strapsruns under a user's chin to secure the user's head in the helmetportion.
 23. The protective headgear as set forth in claim 22, wherein:the first strap is secured to the pad with a hook-and-loop fastener; andthe second strap is secured to the pad with a hook-and-loop fastener.24. The protective headgear as set forth in claim 22, further including:a first substrate; and a second substrate; wherein the first strap isstitched to the first substrate; wherein the second strap is stitched tothe second substrate; wherein a surface of the pad includes a firstportion of a hook-and-loop fastener; wherein the first substrateincludes a second portion of the hook-and-loop fastener that is securedto the first portion of the hook-and-loop fastener at a first locationon the pad; and wherein the second substrate includes another secondportion of the hook-and-loop fastener that is secured to the firstportion of the hook-and-loop fastener at a second location on the pad.25. The protective headgear as set forth in claim 24, wherein: the firstsubstrate is at least about 2 inches²; the second substrate is at leastabout 2 inches²; the first strap is about 5 ¼″ long and about ¾″ wide;and the second strap is about 5 ¼″ long and about ¾″ wide.